I have the same problem with my Kapex trying to cut square: I can align the fence left-right within .001" but if I adjust the saw for square with the workpiece held against the left fence I get a fat 1/32" out of square in 7" on the right side of the fence.
The box from Festool service just came today, I'll be sending it in on Monday.
I'm on my second fence casting, the first one was abysmal and Festool sent me a new one under warranty. I should have sent the saw back then, the saw still doesn't cut reliably square after many hours of futzing around with Starrett straightedges, feeler gauges and lots of NSFW language.
But the blade guard hasn't given me a problem in the 6+ years I've owned the saw. That may be because I don't use it much since it doesn't cut square.
I'd suggest you need to send it in for repair while it's still under warranty. And check it thoroughly when it comes back.